Causes of common problems encountered during welding of aluminium
|
|
- Shawn Moore
- 7 years ago
- Views:
Transcription
1 Causes of common problems encountered during welding of aluminium This chapter presents metallurgical aspects related with welding of aluminium alloys. Causes of common problems encountered during welding of aluminium alloys have been described. The mechanism of solidification cracking and its control has been elaborated in detail. Keywords: Aluminium welding, heat treatable aluminium alloy, precipitation hardening, problems in aluminium welding, inclusion, gas and shrinkage porosity, solidification cracking, controlling solidification cracks 38.1 Need of aluminium welding Welding of the aluminium is considered to be slightly difficult than the steel due to high thermal & electrical conductivity, high thermal expansion coefficient, refractory aluminium oxide (Al 2 O 3 ) formation tendency, and low stiffness. However, increase in applications of aluminium alloys in all sectors of industry is a driving force for technologists to develop viable and efficient technologies for joining of aluminium without much adverse effect on their mechanical, chemical and metallurgical performances desired for longer life. The performance of weld joints of an aluminium alloys to a great extent is determined by its composition, alloy temper condition and method of manufacturing besides welding related parameters. All the three aspects are usually included in aluminium alloy specification. Aluminium alloy may be produced either only by cast or by casting and subsequent forming process (which are called wrought alloys). Welding of wrought aluminium alloys is more common and therefore in this chapter discussions are related to wrought aluminium alloys. Depending upon the composition, aluminium alloy are classified from 1XXX through 9XXX series. Some of aluminum alloys (1XXX, 3XXX, 4XXX and 5XXX) non-heat treatable and others (2XXX, 6XXX and 7XXX series) are heat treatable Strengthening of Non-heat treatable aluminium alloys and welding The strength of the non-heat treatable aluminium alloys is mostly dictated by solid solution strengthening and dispersion hardening effects of alloying elements such as silicon, iron, manganese and magnesium. Magnesium is the most effective alloying
2 element in solution strengthening therefore 5XXX series aluminium alloys have relatively high strength even in annealed condition. Most of the non heat treatable aluminium alloys are work hardenable. Heating of these alloys during welding (due to weld thermal cycle) lowers prior work hardening effect and improves the ductility which in turn can lead to loss of strength of HAZ. Moreover, high strength solid solution alloys of 5XXX series such as Al-Mg and Al-Mg-Mn are found suitable for welded construction structures as they offer largely uniform mechanical properties of the various zones of a welded joint Strengthening of heat treatable aluminium alloys and welding The most of heat treatable aluminium alloys (2XXX, 6XXX and 7XXX series) are strengthened by solid solution formation, work hardening and precipitation strengthening depending upon the alloy condition and manufacturing history. Strength of these alloys in annealed condition is either similar or slightly better as compared to non-heat treatable alloys mainly due to presence of alloying elements such as copper, magnesium, zinc and silicon. Generally, heat treatable aluminium alloys are precipitation hardened. The precipitation hardening involves solutionizing followed by quenching and aging either at room temperature (natural aging) or elevated temperature (artificial aging). Three most common precipitation hardenable aluminium alloys namely Al-Cu (2XXX series), Al-Mg-Si (6XXX series) and Al-Zn-Mg (7XXX series) are primarily hardened by forming phases namely Al 2 Cu, Mg 2 Si and Zn 2 Mg respectively besides many complex intermetallic compounds developed during aging process. Therefore, presence and loss of these precipitates significantly affects the mechanical performance (hardness, tensile strength and % elongation) of weld joints of these alloys. However, the existence of theses hardening precipitates is influenced by weld thermal cycle experienced by base metal and weld metal during welding. In general, all factors decreasing the heat input (either due to low welding current, increase in welding speed or use of low heat input welding processes such as electron beam, pulse TIG) would reduce the width of heat affected zone associate adverse effects such as the possibility of partial melting of low melting point phases (eutectic)
3 present at grain boundary, over-aging, grain growth, reversion or dissolution of precipitates or a combination few or all. In the solution heat treated condition, heat treatable alloys exhibit lower cracking tendency than in the aged condition mainly due to more uniform microstructure and lesser restraint imposed by base metal. Welding of heat treatable aluminium alloy in aged condition leads to reversion (loss/dissolution of precipitates) and over-aging (coarsening of precipitates by consuming fine precipitates) effect which in turn softens the HAZ to some extent. However, under influence welding thermal cycle, alloying elements are dissolved during heating and form heterogeneous solid solution and subsequently rapid cooling results in super-saturation of these elements in aluminium matrix. Thus, solutionizing and quenching influence the heat affected zone. Thereafter, aging of some of the alloys like Al-Zn-Mg occurs slowly even at room temperature which in turn help to attain strength almost similar to that of base metal while other heat treatable alloy like Al-Cu and Al-Mg-Si alloys don t show appreciable age hardening at room temperature. Hence, Al-Zn-Mg alloys are preferred when post weld heat treatment is neither possible nor feasible Weldability of aluminum alloys Weldability of aluminium alloys like any other metal system must be assessed in light of purpose (application of weld joint considering service conditions), welding procedure being used and welding conditions in which welding need to be performed. Weldability of aluminium may be very poor when joined by shielded metal arc welding or gas welding but the same may be very good when joint is made using tungsten inert gas or gas metal arc welding process. Similarly other aspects of welding procedure such as edge preparation, welding parameters, preheat and post weld heat treatment etc. can significantly dictate the weldability of aluminium owing to their ability to affect the soundness of weld joints and mechanical performance. Thus, all the factors governing the soundness of the aluminium weld, the mechanical and
4 metallurgical features determine the weldability of aluminium alloy system. In general, aluminium is considered to be of comparatively lower weldability than steels due to various reasons a) high affinity of aluminium towards atmospheric gases, b) high thermal expansion coefficient, c) high thermal and electrical conductivity, d) poor rigidity and e) high solidification temperature range. These characteristics of aluminium alloys in general make them sensitive from defect formation point of view during welding. The extent of undesirable affect of above characteristics on performance of the weld joints is generally reduced using two approaches a) effective protection of the weld pool contamination from atmospheric gases using proper shielding method and b) reducing influence of weld thermal cycling using higher energy density welding processes. Former approach mainly deals with using various environments (vacuum, Ar, He, or their mixtures with hydrogen and oxygen) to shield the weld pool from ambient gases while later one has led to the development of newer welding processes such as laser, pulse variants of TIG and MIG, friction stir welding etc Typical welding problems in aluminum alloys Porosity Porosity in aluminum weld joints can be of two types a) hydrogen induced porosity and b) interdendritic shrinkage porosity and both are caused by entirely different factors (Fig. 38.1). Former one is caused by the presence of hydrogen in the weld owing to unfavorable welding conditions such as improper cleaning, moisture in electrode, shielding gases and oxide layer, presence of hydro-carbons in form of oil, paint, grease etc. In presence of hydrogen porosity in the weld metal mainly occurs due to high difference in solubility of hydrogen in liquid and solid state of aluminum alloy. During solidification of the weld metal, the excess hydrogen is rejected at the advancing solid-liquid interface in the weld which in turn leads to the development of hydrogen induced porosity especially under high solidification rate conditions as high cooling rate experienced by the weld pool increases tendency of entrapment of hydrogen. Excessive hydrogen porosity can severely reduce strength, ductility and fatigue resistance of aluminum welds due to two reasons a) reduction in effective load resisting cross-sectional area of the weld joints and b) loss of metallic continuity owing to the presence of gas pockets which in turn increases the stress concentration at the weld pores. It also reduces the life of aluminum welds. Therefore, to control hydrogen induced porosity in aluminium following approaches can be used a) proper cleaning of surfaces, baking of the electrodes to drive off moisture and
5 remove the impurities from weld surface b) addition of freon to the shielding gas, c) churning the weld pool during weld solidification using suitable electro-magnetic fields. Inter-dendritic porosity in weld mainly occurs due to poor fluidity of molten weld metal and rapid solidification. Preheating of plates and increasing heat input (using high current and low welding speed) help in reducing the inter-dendritic porosity. Fig Micrographs showing a) dendritic and b) gas porosity in aluminium welds (100X) Inclusion In general, presence of any foreign constituent (one which is not desired) in the weld can be considered as inclusion and these may be in the form of gases, thin films and solid particles. High affinity of aluminium with atmospheric gases increases the tendency of formation of oxides and nitrides (having density similar to that of aluminium) especially when a) protection of weld pool is not enough, b) proper cleaning of filler and base metal has not been done, c) shielding gases are not pure enough and therefore making oxygen and hydrogen available to molten weld pool during welding, d) gases are present in dissolved state in aluminium itself and tungsten inclusion while using GTA welding. Mostly, inclusion of oxides and nitrides of aluminium are found in weld joints in case of un-favourable welding conditions. Presence of these inclusions disrupts the metallic continuity in the weld therefore these provide site for stress concentration and become a source of weakness leading to the deterioration in mechanical and corrosion performance of the weld joints (Fig. 38.2). Ductility, notch toughness and fatigue resistance of the weld joints are very adversely affected by the presence of the inclusion. To reduce the formation of inclusion in weld it is important to give proper attention to a) avoid sources of atmospheric gases, b) developing proper welding procedure specification (selection of proper electrode, welding parameters, shielding gases and manipulation of during
6 welding), and c) manipulation of GTAW torch properly so as to avoid the formation of tungsten inclusion. Fig Inclusions and other impurities in weld joints Solidification cracking This is an inter-dendritic type of cracking mostly along observed along the weld centerline in very last stage of solidification primarily due to two factors a) development of tensile residual stresses and b) presence of low melting point phases in inter-dendritic regions of solidifying weld is called solidification cracking (Fig. 38.3). The solidification cracking mainly occurs when residual tensile stress developed in weld (owing to contraction of base metal and weld metal) goes beyond the strength of solidifying weld metal. Moreover, the contribution of solidification shrinkage of weld metal in development of the tensile residual stress is generally marginal. All the factors namely thermal expansion coefficient of weld and base metal, melting point, weld bead profile, type of weld, degree of constraint, thickness of work piece etc. affecting the contraction of the weld will govern the residual stresses and so solidification cracking tendency. The presence of tensile or shear stress is mandatory for cracking means no residual tensile stress no cracking. Residual stresses in weld joint can not be eliminated but can be minimized by developing proper welding procedure. Increase in degree of restraint during welding in general increases solidification cracking tendency due to increased residual tensile stresses. Similarly, concave fillet weld bead profile results higher solidification cracking tendency than those of convex weld bead profile. In same line, other related materials characteristics of base metal such as increase in thickness of plate, high thermal expansion of coefficient and wider solidification temperature in general increases the residual stresses and so solidification cracking tendency. Apart from the residual tensile stresses, strength and ductility of weld metal in terminal stage of solidification also predominantly determine the solidification cracking tendency. In general, all the factors such as composition of the weld metal, microstructure, segregation tendency, wider
7 solidification temperature range and higher fluidity of low melting point phases (owing to reduction in surface tension and viscosity) of molten weld metal increase the solidification cracking. Fig Solidification cracking in aluminium weld Composition of aluminum alloy Presence of all alloying element (silicon, copper, magnesium, zinc) in such a quantity that increases the solidification temperature range tends to increase the solidification cracking tendency. In general, addition of these elements in aluminum first widens the solidification temperature range then after reaching maximum it decreases gradually as evident from the Fig It can be observed that addition of these elements at certain level results in maximum range of solidification temperature and that corresponds to highest solidification cracking tendency. It can be noticed from the Fig that solidification cracking is lower with both very low and high concentration of alloying element owing to varying amount of low melting point eutectic and other phases. A very limited amount of low melting point phases obviously increases resistance to solidification cracking due to high strength of solidified weld metal in terminal stage of solidification while in case of aluminium alloy (such as eutectic or near to the eutectic composition) or those with high concentration of alloying elements having large amount of low melting point phases to facilitate healing of cracks by the backfill of incipient cracks which in turn decreases the solidification cracking tendency. Therefore, selection of filler metal for welding of aluminum alloys is done in such a way that for given dilution level, concentration of alloying element in weld metal corresponds to minimum solidification temperature so as to reduce the solidification cracking possibility. In general, application of Al-5%Mg and Al-(5-12%) Si fillers are commonly used to avoid solidification cracking during welding of aluminum alloys.
8 Al-Cu Hot cracking sensitivity 0 0 Al-Mg Al-Si Alloying elements (wt.%) Fig Influence alloying elements on solidification cracking tendency The influence of microstructure of weld metal on solidification cracking depends on the way it affects the segregation tendency owing to variation in size and orientation of grains. In general, fine grain structure results is large grain boundary area and hence more uniform distribution of low melting point phases and reduced segregation of alloying element. Further, fine equiaxed grain structure provides better heeling of incipient crack through back fill by liquid metal available at last to solidify due to improved fluidity of melt through the micro-channel present between already solidified metal. Conversely for a given solidification cracking sensitive alloy composition coarse columnar grain structure having abutting orientation encourages the cracking tendency as compared to fine equiaxed and axially grain (Fig. 38.5). Moreover, the morphology of low melting point phases as governed by their surface tension and viscosity in liquid state near last stage of solidification also affects the solidification cracking sensitivity. In general, low melting point phases having low surface tension and viscosity (so high fluidity) solidify in form of thin films and layer in inter-dendritic regions which are considered to be more crack sensitive than those of globular morphology formed in case of high surface tension and viscous low melting point phases.
9 columnar grains weld pool of elipitcal shape axial grains a) columnar grains weld pool of trapezoidal shape b) Fig Schematic diagram showing influence of welding speed on weld pool and grain structure of weld a) low speed and b) high speed Control of solidification cracking Changing composition of the weld metal so as to reduce the solidification temperature range and increase the amount of low melting point eutectic phases and phase mixtures to facilitate heating of incipient cracks. Refinement of the grain structure: The microstructure of weld metal can be controlled in many ways such as addition of grain refiner, use of external electromagnetic or mechanical forces and selection of proper welding parameters such as heat input (VI) and welding speed or use pulse current for welding. Addition of grain refiner (Ti, B, Zr etc) in aluminium weld metal so as to facilitate the development of fine and equiaxed grain structure and reduce columnar grain structure. Similarly, low heat input leads to development of fine equiaxed grains and low welding speed produces curved grain associated with pear drop shaped weld pool. Mechanical vibrations and electromagnetic stirring of weld pool also help to refine the grain structure avoid the abutting columnar grains (Fig b).
10 Reducing tensile residual stresses developing in weld joints using any of the approaches such as controlling weld bead geometry, selection of weld joint design, welding procedure and low strength filler can help in reducing the solidification cracking. References and books for further reading Sindo Kou, Welding metallurgy, John Willey, 2003, 2 nd edition, USA. J F Lancaster, Metallurgy of Welding, Abington Publishing, 1999, 6 th edition, England. Metals Handbook-Welding, Brazing and Soldering, American Society for Metals, 1993, 10 th edition, Volume 6, USA. S V Nadkarni, Modern Arc Welding Technology, Ador Welding Limited, 2010, New Delhi. Welding handbook, American Welding Society, 1987, 8th edition, volume 1 & 2, USA. N R Mandal, Aluminium Welding, Narosa Publications, New Delhi, 2005, 2 nd edition. Sidney H Avner, Introduction to Physical Metallurgy, McGraw Hill, 2009, 2 nd edition, New Delhi.
Problems in Welding of High Strength Aluminium Alloys
Singapore Welding Society Newsletter, September 1999 Problems in Welding of High Strength Aluminium Alloys Wei Zhou Nanyang Technological University, Singapore E-mail: WZhou@Cantab.Net Pure aluminium has
More informationLecture: 33. Solidification of Weld Metal
Lecture: 33 Solidification of Weld Metal This chapter presents common solidification mechanisms observed in weld metal and different modes of solidification. Influence of welding speed and heat input on
More informationWeld Cracking. An Excerpt from The Fabricators' and Erectors' Guide to Welded Steel Construction. The James F. Lincoln Arc Welding Foundation
Weld Cracking An Excerpt from The Fabricators' and Erectors' Guide to Welded Steel Construction The James F. Lincoln Arc Welding Foundation Weld Cracking Several types of discontinuities may occur in welds
More informationAutogenous Laser Welding of Aluminum
Hans Leidich OEM Laser Specialist Laser Technology Center TRUMPF Inc. Why Autogenous Simpler Less hardware Easier process Faster speed Should be first approach (if doesn t work, then go to the next step)
More informationWJM Technologies excellence in material joining
Girish P. Kelkar, Ph.D. (562) 743-7576 girish@welding-consultant.com www.welding-consultant.com Weld Cracks An Engineer s Worst Nightmare There are a variety of physical defects such as undercut, insufficient
More informationAluminum Alloys. casting or a semisolid casting
Functionality & Service Requirements When determining how a component will function, the first question to ask is: what purpose will the component serve? Choosing the alloy, casting process and thermal
More informationChapter 5 - Aircraft Welding
Chapter 5 - Aircraft Welding Chapter 5 Section A Study Aid Questions Fill in the Blanks 1. There are 3 types of welding:, and, welding. 2. The oxy acetylene flame, with a temperature of Fahrenheit is produced
More informationMSE 528 - PRECIPITATION HARDENING IN 7075 ALUMINUM ALLOY
MSE 528 - PRECIPITATION HARDENING IN 7075 ALUMINUM ALLOY Objective To study the time and temperature variations in the hardness and electrical conductivity of Al-Zn-Mg-Cu high strength alloy on isothermal
More informationThe study about as cast microstructure and solidification
The study about as cast microstructure and solidification process of Al-Mg-Si alloys Introduction High-strength and high formability aluminum alloys are the highly demanded alloy in automobile industry,
More informationCENTRIFUGAL CASTING. Email: amitjoshi@iitb.ac.in amitjoshi1000@yahoo.ca
CENTRIFUGAL CASTING Amit M Joshi (B.Engg. Mechanical, A.M.I.Prod.E, A.I.E) Dept. of Metallurgical Engg. & Material Science, Indian Institute of Technology Bombay, India. Email: amitjoshi@iitb.ac.in amitjoshi1000@yahoo.ca
More informationFEATURES AND BENEFITS OF DIFFERENT PLATINUM ALLOYS. Kris Vaithinathan and Richard Lanam Engelhard Corporation
FEATURES AND BENEFITS OF DIFFERENT PLATINUM ALLOYS Kris Vaithinathan and Richard Lanam Engelhard Corporation Introduction There has been a significant increase in the world wide use of platinum for jewelry
More informationCopper Alloys COPPER ALLOYS. Weld Tech News VOL 1. NO. 8
Copper Alloys Weld Tech News VOL 1. NO. 8 WELD TECH NEWS is a newsletter for welders working primarily in maintenance and repair. Each issue contains useful information on materials (cast irons, steels,
More informationThe mechanical properties of metal affected by heat treatment are:
Training Objective After watching this video and reviewing the printed material, the student/trainee will learn the basic concepts of the heat treating processes as they pertain to carbon and alloy steels.
More informationWelding. ArcelorMittal Europe Flat Products. Definitions of welding and weldability. Consequences of welding
ArcelorMittal Europe Flat Products Welding Definitions of welding and weldability Welding of metal parts is a joining process designed to ensure metallic continuity across the joint. This continuity is
More informationEML 2322L MAE Design and Manufacturing Laboratory. Welding
EML 2322L MAE Design and Manufacturing Laboratory Welding Intro to Welding A weld is made when separate pieces of material to be joined combine and form one piece when heated to a temperature high enough
More informationWelding. Module 19.2.1
Welding Module 19.2.1 Hard Soldering Hard soldering is a general term for silver soldering and brazing. These are very similar thermal joining processes to soft soldering in as much that the parent metal
More informationNorth American Stainless
North American Stainless Long Products Stainless Steel Grade Sheet 2205 UNS S2205 EN 1.4462 2304 UNS S2304 EN 1.4362 INTRODUCTION Types 2205 and 2304 are duplex stainless steel grades with a microstructure,
More informationCopper. Consumables. Copper and Copper Alloys. Welding Processes
Consumables and Alloys is a metal with some very important properties, the main ones being its high electrical conductivity, its high thermal conductivity, its excellent resistance to corrosion, and its
More informationDuplex Stainless Steel Fabrication. Gary M. Carinci TMR Stainless Consultant for International Molybdenum Association
Duplex Stainless Steel Fabrication Gary M. Carinci TMR Stainless Consultant for International Molybdenum Association 1 Promoting molybdenum - as a material with superior properties and performance in a
More informationStructural Steel Welding
PDH Course S150 Structural Steel Welding Semih Genculu, P.E. 2007 PDH Center 2410 Dakota Lakes Drive Herndon, VA 20171-2995 Phone: 703-478-6833 Fax: 703-481-9535 www.pdhcenter.com An Approved Continuing
More informationWORD DEFINITION WORD (NATIONAL LANGUAGE)
WELDING GLOSSARY The Glossary has been created as part of the Migration for Development in the Western Balkans (MIDWEB) project, which received financial assistance from the European Commission IPA 2009
More informationAluminum Metallurgy What Metal Finishers Should Know
Help Log-in Site News Home About Us Services Publications Links Contact Us Accreditation Q & A Forums Print This Document Back again for installment #5 of the Omega Update! This past summer we began our
More informationNorth American Stainless
North American Stainless Flat Products Stainless Steel Grade Sheet 310S (S31008)/ EN 1.4845 Introduction: SS310 is a highly alloyed austenitic stainless steel designed for elevated-temperature service.
More informationHEAT TREATMENT OF STEEL
HEAT TREATMENT OF STEEL Heat Treatment of Steel Most heat treating operations begin with heating the alloy into the austenitic phase field to dissolve the carbide in the iron. Steel heat treating practice
More informationSAND CAST CHILL CAST LM4 - TF
1 This alloy conforms with British Standards 1490 and is similar to the obsolete specifications BS.L79 and D.T.D 424A. Castings may be in the cast (M) of fully heat treated (TF) conditions. CHEMICAL COMPOSITION
More informationASTM A860/A860M-09 Standard Specification for Wrought High Strength. Ferritic Steel Butt Welding Fittings. 1. Scope :- 2. Reference Documents :-
Standard Specification for Wrought High Strength Ferritic Steel Butt Welding Fittings 1. Scope :- 1.1 This specification covers wrought high strength ferritic steel butt-welding fitting of seamless and
More informationPRECIPITATION AND SOFTENING BEHAVIOUR OF CAST, COLD ROLLED AND HOT ROLLING PRIOR TO COLD ROLLED AL-6MG ALLOY ANNEALED AT HIGH TEMPERATURE
Precipitation and softening behaviour of cast, cold rolled and hot rolling prior 32 PRECIPITATION AND SOFTENING BEHAVIOUR OF CAST, COLD ROLLED AND HOT ROLLING PRIOR TO COLD ROLLED AL-MG ALLOY ANNEALED
More informationNorth American Stainless
North American Stainless Flat Products Stainless Steel Sheet T409 INTRODUCTION NAS 409 is an 11% chromium, stabilized ferritic stainless steel. It is not as resistant to corrosion or high-temperature oxidation
More informationHeat Treatment of Aluminum Foundry Alloys. Fred Major Rio Tinto Alcan
Heat Treatment of Aluminum Foundry Alloys Fred Major Rio Tinto Alcan OUTLINE Basics of Heat Treatment (What is happening to the metal at each step). Atomic Structure of Aluminum Deformation Mechanisms
More informationLASER CUTTING OF STAINLESS STEEL
LASER CUTTING OF STAINLESS STEEL Laser inert gas cutting is the most applicable process type used for cutting of stainless steel. Laser oxygen cutting is also applied in cases where the cut face oxidation
More informationLecture slides on rolling By: Dr H N Dhakal Lecturer in Mechanical and Marine Engineering, School of Engineering, University of Plymouth
Lecture slides on rolling By: Dr H N Dhakal Lecturer in Mechanical and Marine Engineering, School of Engineering, University of Plymouth Bulk deformation forming (rolling) Rolling is the process of reducing
More informationObjectives/Introduction Extraction of zinc Physical properties of zinc Zinc casting alloys Wrought zinc alloys Engineering design with zinc alloys
Lecture 7 Zinc and its alloys Subjects of interest Objectives/Introduction Extraction of zinc Physical properties of zinc Zinc casting alloys Wrought zinc alloys Engineering design with zinc alloys Objectives
More informationFriction Surfacing of Austenitic Stainless Steel on Low Carbon Steel: Studies on the Effects of Traverse Speed
, June 30 - July 2, 2010, London, U.K. Friction Surfacing of Austenitic Stainless Steel on Low Carbon Steel: Studies on the Effects of Traverse Speed H. Khalid Rafi, G. D. Janaki Ram, G. Phanikumar and
More informationNorth American Stainless
Introduction: North American Stainless Flat Products Stainless Steel Grade Sheet 309S (S30908)/ EN1.4833 SS309 is a highly alloyed austenitic stainless steel used for its excellent oxidation resistance,
More informationThe Metallurgy of Copper Wire By Dr. Horace Pops Director-Metals Laboratory Superior Essex Industries
The Metallurgy of Copper Wire By Dr. Horace Pops Director-Metals Laboratory Superior Essex Industries Introduction Copper is the preferred and predominant choice in the electrical industry because of its
More informationField Welding Inspection Guide
Field Welding Inspection Guide Assistance in interpretation of any specification or questions concerning field welding issues can be obtained from the Office of Materials Management, Structural Welding
More informationLecture 35: Atmosphere in Furnaces
Lecture 35: Atmosphere in Furnaces Contents: Selection of atmosphere: Gases and their behavior: Prepared atmospheres Protective atmospheres applications Atmosphere volume requirements Atmosphere sensors
More informationPOURING THE MOLTEN METAL
HEATING AND POURING To perform a casting operation, the metal must be heated to a temperature somewhat above its melting point and then poured into the mold cavity to solidify. In this section, we consider
More informationAUSTENITIC STAINLESS DAMASCENE STEEL
AUSTENITIC STAINLESS DAMASCENE STEEL Damasteel s austenitic stainless Damascene Steel is a mix between types 304L and 316L stainless steels which are variations of the 18 percent chromium 8 percent nickel
More informationAging and Mechanical Behavior of Be-Treated 7075 Aluminum Alloys
Aging and Mechanical Behavior of Be-Treated 7075 Aluminum Alloys Mahmoud M. Tash, S. Alkahtani Abstract The present study was undertaken to investigate the effect of pre-aging and aging parameters (time
More informationA Multilayer Clad Aluminum Material with Improved Brazing Properties
A Multilayer Clad Aluminum Material with Improved Brazing Properties An interlayer between cladding and core is shown to be an effective barrier against silicon penetration during brazing BY H. ENGSTROM
More informationNorth American Stainless
North American Stainless Flat Products Stainless Steel Grade Sheet 304 (S30400)/ EN 1.4301 304L (S30403) / EN 1.4307 304H (S30409) Introduction: Types 304, 304L and 304H are the most versatile and widely
More informationAblation of Hybrid Metal Matrix Composites
Paper 11-057.pdf, Page 1 of 7 Copyright 2011 American Foundry Society Ablation of Hybrid Metal Matrix Composites D. Weiss Eck Industries, Manitowoc, WI J. Grassi Alotech LLC Ltd., Brooklyn, OH B. Schultz,
More informationALLOY 2205 DATA SHEET
ALLOY 2205 DATA SHEET UNS S32205, EN 1.4462 / UNS S31803 GENERAL PROPERTIES ////////////////////////////////////////////////////// //// 2205 (UNS designations S32205 / S31803) is a 22 % chromium, 3 % molybdenum,
More informationDefects Introduction. Bonding + Structure + Defects. Properties
Defects Introduction Bonding + Structure + Defects Properties The processing determines the defects Composition Bonding type Structure of Crystalline Processing factors Defects Microstructure Types of
More information3.3 Welding and welded connections
3.3 Welding and welded connections Welding is the process of joining two pieces of metal by creating a strong metallurgical bond between them by heating or pressure or both. It is distinguished from other
More informationUnit 6: EXTRUSION. Difficult to form metals like stainless steels, nickel based alloys and high temperature metals can also be extruded.
1 Unit 6: EXTRUSION Introduction: Extrusion is a metal working process in which cross section of metal is reduced by forcing the metal through a die orifice under high pressure. It is used to produce cylindrical
More informationHigh Strength and Wear Resistant Aluminum Alloy for High Temperature Applications
High Strength and Wear Resistant Aluminum Alloy for High Temperature Applications JONATHAN A. LEE NASA-Marshall Space Flight Center (MSFC) Mail Code ED33 Huntsville, AL 35812 Email: Jonathan.Lee@msfc.nasa.gov
More informationPhase. Gibbs Phase rule
Phase diagrams Phase A phase can be defined as a physically distinct and chemically homogeneous portion of a system that has a particular chemical composition and structure. Water in liquid or vapor state
More information8. Technical Heat Treatment
8. Technical Heat Treatment 8. Technical Heat Treatment 95 6 cm 4 2 0-2 -4 C 400 C C -6-14 -12-10 -8-6 -4-2 0 2 cm 6 723 C temperature C 1750 750 250 When welding a workpiece, not only the weld itself,
More informationMetals and Non-metals. Comparison of physical properties of metals and non metals
Metals and Non-metals Comparison of physical properties of metals and non metals PHYSICAL PROPERTY METALS NON-METALS Physical State Metallic lustre (having a shining surface) Mostly solids (Liquid -mercury)
More informationIron-Carbon Phase Diagram (a review) see Callister Chapter 9
Iron-Carbon Phase Diagram (a review) see Callister Chapter 9 University of Tennessee, Dept. of Materials Science and Engineering 1 The Iron Iron Carbide (Fe Fe 3 C) Phase Diagram In their simplest form,
More informationEngine Bearing Materials
Engine Bearing Materials Dr. Dmitri Kopeliovich (Research & Development Manager) The durable operation of an engine bearing is achieved if its materials combine high strength (load capacity, wear resistance,
More informationSection 4: NiResist Iron
Section 4: NiResist Iron Section 4 Ni-Resist Description of Grades...4-2 201 (Type 1) Ni-Resist...4-3 202 (Type 2) Ni-Resist...4-6 Stock Listings...4-8 4-1 Ni-Resist Description of Grades Ni-Resist Dura-Bar
More informationCorrosion-induced cracking of model train zincaluminium
Nationaal Lucht- en Ruimtevaartlaboratorium National Aerospace Laboratory NLR Corrosion-induced cracking of model train zincaluminium die castings R.J.H. Wanhill and T. Hattenberg This report may be cited
More information2 MATTER. 2.1 Physical and Chemical Properties and Changes
2 MATTER Matter is the material of which the universe is composed. It has two characteristics: It has mass; and It occupies space (i.e., it has a volume). Matter can be found in three generic states: Solid;
More informationLaser sintering of greens compacts of MoSi 2
Laser sintering of greens compacts of MoSi 2 G. de Vasconcelos 1, R. Cesar Maia 2, C.A.A.Cairo 3, R. Riva 2, N.A.S.Rodrigues 2, F.C.L.Mello 3 Instituto de Estudos Avançados 1, Instituto Tecnológico de
More informationALLOY 6022 SHEET. Higher Strength with Improved Formability SUPPLYING THE WORLD S BEST
SUPPLYING THE WORLD S BEST DESCRIPTION 6022 is a heat treatable low copper, Al-Si-Mg sheet alloy developed by Alcoa to satisfy the needs of automotive manufacturers for closure panels, such as a hood,
More informationINDIAN STANDARDS (BIS) ON WELDING
** IS 82:957 Glossary of terms relating to welding and cutting of Sep 2008 metals 2 IS 83:986 Scheme of symbols for welding (revised) Sep 2008 3 IS 84:2004 Covered electrodes for manual metal arc welding
More informationCh. 4: Imperfections in Solids Part 1. Dr. Feras Fraige
Ch. 4: Imperfections in Solids Part 1 Dr. Feras Fraige Outline Defects in Solids 0D, Point defects vacancies Interstitials impurities, weight and atomic composition 1D, Dislocations edge screw 2D, Grain
More informationHigh-strength and ultrahigh-strength. Cut sheet from hot-rolled steel strip and heavy plate. voestalpine Steel Division www.voestalpine.
High-strength and ultrahigh-strength TM steels Cut sheet from hot-rolled steel strip and heavy plate Josef Elmer, Key account manager voestalpine Steel Division www.voestalpine.com/steel Weight savings
More informationLecture 19: Eutectoid Transformation in Steels: a typical case of Cellular
Lecture 19: Eutectoid Transformation in Steels: a typical case of Cellular Precipitation Today s topics Understanding of Cellular transformation (or precipitation): when applied to phase transformation
More informationALLOY C276 DATA SHEET
ALLOY C276 DATA SHEET //// Alloy C276 (UNS designation N10276) is a nickel-molybdenum-chromium-iron-tungsten alloy known for its corrosion resistance in a wide range of aggressive media. It is one of the
More information2.3. Continuous Hot-Dip Galvanizing versus General (Batch) Galvanizing Rev 1.0 Jan 2011. GalvInfoNote. Introduction. Continuous Galvanizing
2. Coating Processes and Surface Treatments GalvInfoNote 2.3 Introduction Continuous Hot-Dip Galvanizing versus General (Batch) Galvanizing There are two different processes for applying a zinc coating
More informationEvaluation of the Susceptibility of Simulated Welds In HSLA-100 and HY-100 Steels to Hydrogen Induced Cracking
Evaluation of the Susceptibility of Simulated Welds In HSLA-100 and HY-100 Steels to Hydrogen Induced Cracking R. E. Ricker, M. R. Stoudt, and D. J. Pitchure Materials Performance Group Metallurgy Division
More informationAluminium as Construction Material in Ammonia Refrigeration Cycles
Aluminium as Construction Material in Ammonia Refrigeration Cycles Experiences With Aluminium Compared to other metals, aluminium has only a brief history as an engineering material. While, about 150 years
More information% Si Fe Cu Mn Mg Cr Zn Ti Others Others. Europe USA Spain France Germany G.B. Italy Sweden Switzerland Japan. ALMgSi1 3.3215 H30
ALUMINIUMS Alloys Aluminium - Magnesium - Silicon 6082 % Si Fe Cu Mn Mg Cr Zn Ti Others Others Minimum 0,70 0,40 0,60 Each Total Maximum 1,30 0,50 0,10 1,00 1,20 0,25 0,20 0,10 0,05 0,10 Europe USA Spain
More informationDer Einfluss thermophysikalischer Daten auf die numerische Simulation von Gießprozessen
Der Einfluss thermophysikalischer Daten auf die numerische Simulation von Gießprozessen Tagung des Arbeitskreises Thermophysik, 4. 5.3.2010 Karlsruhe, Deutschland E. Kaschnitz Österreichisches Gießerei-Institut
More information2017A ALUMINUM ALLOY IN DIFFERENT HEAT TREATMENT CONDITIONS
Acta Metallurgica Slovaca, Vol. 18, 2012, No. 2-3, p. 82-91 82 2017A ALUMINUM ALLOY IN DIFFERENT HEAT TREATMENT CONDITIONS K. Mroczka 1)*, A. Wójcicka 1), P. Kurtyka 1) 1) Department of Technology and
More informationTIE-31: Mechanical and thermal properties of optical glass
PAGE 1/10 1 Density The density of optical glass varies from 239 for N-BK10 to 603 for SF66 In most cases glasses with higher densities also have higher refractive indices (eg SF type glasses) The density
More informationNorth American Stainless
North American Stainless Flat Products Stainless Steel Grade Sheet 430 (S43000)/ EN 1.4016 Introduction: SS430 is a low-carbon plain chromium, ferritic stainless steel without any stabilization of carbon
More informationME349 Engineering Design Projects
ME349 Engineering Design Projects Introduction to Materials Selection The Material Selection Problem Design of an engineering component involves three interrelated problems: (i) selecting a material, (ii)
More informationWear-resistant steels. Technical terms of delivery for heavy plates. voestalpine Grobblech GmbH www.voestalpine.com/grobblech
Wear-resistant steels Technical terms of delivery for heavy plates voestalpine Grobblech GmbH www.voestalpine.com/grobblech Wear-resistant steels durostat durostat 400 durostat 450 durostat 500 durostat
More informationNorth American Stainless
North American Stainless Flat Product Stainless Steel Grade Sheet 316 (S31600)/EN 1.4401 316L (S31603)/ EN 1.4404 INTRODUCTION NAS provides 316 and 316L SS, which are molybdenum-bearing austenitic stainless
More informationStructural welding is a process by which the parts that are to be connected are heated and
CHAPTER 6. WELDED CONNECTIONS 6.1 INTRODUCTORY CONCEPTS Structural welding is a process by which the parts that are to be connected are heated and fused, with supplementary molten metal at the joint. A
More informationMaterial data sheet. EOS Aluminium AlSi10Mg_200C. Description
EOS Aluminium AlSi10Mg_200C All information in this data sheet refers to the alloy EOS Aluminium AlSi10Mg_200C. This alloy is formed when the powder EOS Aluminium AlSi10Mg is processes at a building platform
More informationSoldering is joining two pieces of metal, using another metal as a filler, generally at temperatures below 1000 F, and usually between 300 to 600 F.
Soldering Weld Tech News VOL 1. NO. 7 WELD TECH NEWS is a newsletter for welders working primarily in maintenance and repair. Each issue contains useful information on materials (cast iron, steels, aluminum,
More informationHeat Treatment of Steels : Spheroidize annealing. Heat Treatment of Steels : Normalizing
Heat Treatment of Steels :Recrystallization annealing The carbon and alloy steels were treated at a temperature of about 700 C, which is about 20 C below the eutectoid temperature. The holding time should
More informationNorth American Stainless
North American Stainless Long Products Stainless Steel Grade Sheet AISI 304 UNS S30400 EN 1.4301 AISI 304L UNS S30430 EN 1.4307 INTRODUCTION: Types 304 and 304L are the most versatile and widely used of
More informationMaterial data sheet. EOS Aluminium AlSi10Mg. Description
EOS Aluminium AlSi10Mg EOS Aluminium AlSi10Mg is an aluminium alloy in fine powder form which has been specially optimised for processing on EOSINT M systems This document provides information and data
More informationTechnical Data BLUE SHEET. Martensitic. stainless steels. Types 410, 420, 425 Mod, and 440A GENERAL PROPERTIES APPLICATIONS PRODUCT FORM
Technical Data BLUE SHEET Allegheny Ludlum Corporation Pittsburgh, PA Martensitic Stainless Steels Types 410, 420, 425 Mod, and 440A GENERAL PROPERTIES Allegheny Ludlum Types 410, 420, 425 Modified, and
More informationName: Class: Date: ID: A
Name: Class: Date: ID: A Chapter 2 Assessment Multiple Choice Identify the choice that best completes the statement or answers the question. Complete short answer questions on a separate sheet of paper.
More informationSelective Soldering Defects and How to Prevent Them
Selective Soldering Defects and How to Prevent Them Gerjan Diepstraten Vitronics Soltec BV Introduction Two major issues affecting the soldering process today are the conversion to lead-free soldering
More informationDX2202 Duplex stainless steel
Stainless Europe Grade DX22 Duplex stainless steel Chemical Composition Elements C Mn Cr Ni Mo N %.25.3 23. 2.5
More informationSTAVAX SUPREME. Stainless tool steel
STAVAX SUPREME Stainless tool steel General Demands placed on plastic mould tooling are increasing. Such conditions require mould steels that possess a unique combination of toughness, corrosion resistance
More informationME 612 Metal Forming and Theory of Plasticity. 1. Introduction
Metal Forming and Theory of Plasticity Yrd.Doç. e mail: azsenalp@gyte.edu.tr Makine Mühendisliği Bölümü Gebze Yüksek Teknoloji Enstitüsü In general, it is possible to evaluate metal forming operations
More informationFundamentals of Extrusion
CHAPTER1 Fundamentals of Extrusion The first chapter of this book discusses the fundamentals of extrusion technology, including extrusion principles, processes, mechanics, and variables and their effects
More informationGENERAL PROPERTIES //////////////////////////////////////////////////////
ALLOY 625 DATA SHEET //// Alloy 625 (UNS designation N06625) is a nickel-chromium-molybdenum alloy possessing excellent resistance to oxidation and corrosion over a broad range of corrosive conditions,
More informationChapter Outline: Phase Transformations in Metals
Chapter Outline: Phase Transformations in Metals Heat Treatment (time and temperature) Microstructure Mechanical Properties Kinetics of phase transformations Multiphase Transformations Phase transformations
More informationMICROSTRUCTURAL AND MECHANICAL CHARACTERIZATION OF GRAY CAST IRON AND AlSi ALLOY AFTER LASER BEAM HARDENING
Materials Science Forum Vols. 638-642 (2010) pp 769-774 Online available since 2010/Jan/12 at www.scientific.net (2010) Trans Tech Publications, Switzerland doi:10.4028/www.scientific.net/msf.638-642.769
More informationChapter Outline Dislocations and Strengthening Mechanisms
Chapter Outline Dislocations and Strengthening Mechanisms What is happening in material during plastic deformation? Dislocations and Plastic Deformation Motion of dislocations in response to stress Slip
More informationPhase Transformations in Metals and Alloys
Phase Transformations in Metals and Alloys THIRD EDITION DAVID A. PORTER, KENNETH E. EASTERLING, and MOHAMED Y. SHERIF ( г йс) CRC Press ^ ^ ) Taylor & Francis Group Boca Raton London New York CRC Press
More informationCrystal Structure of Aluminum, Zinc, and their Alloys By: Omar Fajardo Sebastian Henao Devin Baines ENGR45, F2014, SRJC
Crystal Structure of Aluminum, Zinc, and their Alloys By: Omar Fajardo Sebastian Henao Devin Baines ENGR45, F2014, SRJC Purpose The purpose of this experiment was to examine and observe the microstructure
More information